Alignment device and methods

ABSTRACT

In accordance with at least one aspect of this disclosure, an alignment device for assembling a structure having two or more legs includes a base configured to support a pile driver for pile driving at least one of the two or more legs, and a plurality of alignment structures configured to define an alignment opening, connected to the base, and extending at least partially laterally from the base, wherein the plurality of alignment structures are configured to receive a respective leg of the two or more legs to allow the two or more legs to be positioned relative to each other.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Application No. 63/017,364, filed Apr. 29, 2020, the entire contents of which are herein incorporated by reference in their entirety.

BACKGROUND 1. Field

This disclosure relates to alignment devices and methods, e.g., for multi-legged structures.

2. Description of Related Art

Constructing a multi-legged utility tower, for example, requires the use heavy machinery in order to align and drive the legs of the tower into the ground. However, such heavy machinery is not equipped for constructing these structures in environments where the ground is soft or frequently saturated, such as wetlands, or areas of heavy flooding. Using conventional devices and methods in these environments is not practical and adds significant time and financial cost to construct the tower.

Such conventional methods and systems have generally been considered satisfactory for their intended purpose. However, there is still a need in the art for improved alignment devices and methods. The present disclosure provides a solution for this need.

SUMMARY

In accordance with at least one aspect of this disclosure, an alignment device for assembling a structure having two or more legs can include a base configured to support a pile driver for pile driving at least one of the two or more legs, and a plurality of alignment structures configured to define an alignment opening, connected to the base, and extending at least partially laterally from the base. The plurality of alignment structures can be configured to receive a respective leg of the two or more legs to allow the two or more legs to be positioned relative to each other.

Each alignment structure can further include one or more alignment support members connected to each alignment structure and extending into and/or over the alignment opening, and each alignment support member can be configured to contact a leg disposed in the alignment opening. The one or more alignment support members can be complementary to surface of a respective leg and can be positioned to contact the respective leg in flush contact. The one or more alignment support members can be positionably mounted to each alignment structure to allow each alignment support member to be positioned relative to a respective leg disposed within the alignment opening.

In certain embodiments, the plurality of alignment structures can include a complimentary shape to the two or more legs. For example, each alignment structure can be complementary to a caisson having a substantially polygonal shape. In certain embodiments, each alignment structure can have a dodecagon.

The base can form a substantially planar shape, and the alignment opening of each alignment structure can include an opening planar vector that can be substantially parallel to a base planar vector of the planar shape of the base. In certain embodiments, the substantially planar shape can be a square shape.

The base can further include a support frame and a platform supported by the support frame. The base can include a first side and a second side that can be detachably connected to each other along a midline.

The device can also include at least one pair alignment baffles configured to receive a portion of a pile driver on the platform. Each alignment baffle can be configured to receive a foot of a pile driver and/or are complimentary to a shape of a foot of a pile driver. The at least one pair of baffles can be at least one inch in height. The device can include a plurality of connection points that can be configured to connect to a lifting device for lifting and/or transport of the alignment device.

In accordance with at least one aspect of this disclosure, a method can include constructing a structure having a plurality of legs using an alignment device configured to align each leg relative to each other. The method can also include disposing an alignment device onto a surface. Disposing the alignment device can include lowering the alignment device from a helicopter, for example. The method can include disposing a pile driver onto the alignment device. Disposing the pile driver can include lowering the pile driver from a helicopter, for example.

In embodiments, the method can also include placing a first leg of the structure into a first alignment structure of the alignment device, and pile driving the first leg of the structure into the surface using a pile driver supported by the alignment device. The method can include placing a second leg of the structure into a second one of the alignment structures of the alignment device. The method can include turning the pile driver to interact with the second leg and/or to align the pile driver with the second one of the at least one alignment structures, and pile driving the second leg of the structure into the surface using the pile driver.

In accordance with at least one aspect of this disclosure, a method can include constructing a multi-legged utility tower having a plurality of legs on wetland using an alignment device configured to rest on the wetland surface to align at least two of the plurality of legs. The multi-legged utility tower can be an electrical transmission structure, for example.

These and other features of the embodiments of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, embodiments thereof will be described in detail herein below with reference to certain figures, wherein:

FIG. 1 is a perspective view of an embodiment of a device in accordance with this disclosure;

FIG. 2 is a partial perspective view of the alignment device of FIG. 1, shown having a platform and a support frame;

FIG. 3 is a schematic plan view of an embodiment of a base in accordance with this disclosure;

FIG. 4 is schematic plan view of an alignment structure of the device of FIG. 1;

FIG. 5 is a schematic diagram of a portion of the embodiment of FIG. 1;

FIG. 6A is a schematic elevation view of an embodiment of an alignment support member in accordance with this disclosure;

FIGS. 6B-6D show other embodiments of alignment support members in accordance with this disclosure;

FIG. 7 is a schematic plan view of the embodiment of FIG. 4 shown in an open position; the alignment structures can include one or more pieces that form or are configured to selectively form a hoop;

FIG. 8 is a schematic plan view of an embodiment of the embodiment of FIG. 4, shown in the closed position; and

FIG. 9 is a perspective view of the embodiment of FIG. 1 in use in marsh land.

DETAILED DESCRIPTION

Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, an illustrative view of an embodiment of an alignment device in accordance with the disclosure is shown in FIG. 1 and is designated generally by reference character 100. Other embodiments and/or aspects of this disclosure are shown in FIGS. 2-9. Certain embodiments described herein can be used to align and construct large multi-legged structures.

In accordance with at least one aspect of this disclosure, referring to FIGS. 1-9 an alignment device 100 for assembling a structure having two or more legs (e.g. leg 132 as shown in FIG. 9) can include a base 102 configured to support a pile driver (e.g. pile driver 108 shown in FIG. 9) for pile driving at least one of the two or more legs 132. The device 100 can include a plurality of alignment structures 104 a-104 d, each defining a corresponding alignment opening 106 a-106 d, for example. Any suitable number of alignment structures are contemplated herein (e.g., two, three, four as shown, five, etc.).

The alignment structures 104 a-104 d can extend at least partially laterally from the base 102. The plurality of alignment structures 104 a-104 d can be configured to receive (e.g., in abutment with or at least partially containing, bordering, or surrounding) a respective leg of the two or more legs 132 to allow the two or more legs 132 to be positioned relative to each other on or in a surface.

As shown, in certain embodiments, the alignment structures 104 a-104 d can include one or more pieces (e.g. pieces 160 and 162 in FIG. 7) that form or are configured to selectively form a hoop (e.g., for surrounding a leg). For example, one or more of the alignment structures 104 a-104 d can include a hinge 152 and a clasp 150 or any other suitable securement (e.g., chains, locks, etc.) to secure a plurality of pieces 160, 162 together to form a hoop in a closed position. In certain embodiments, the alignment structures 104 a-104 d can comprise a solid member that defines a hoop and does not otherwise move. The hoop shape can be larger in area than the outer diameter/dimension of the leg to be inserted in certain embodiments. It is contemplated that one or more of the alignment structures 104 a-104 d need not have a hoop shape and can form any suitable shape to support and/or align legs of a structure (e.g., a half hoop shape).

The alignment structures 104 a-104 d can be connected to the base 102 with extension arms 110. The extension arms 110 can include a plurality of holes 113 configured to engage a respective pin 111 to secure the extension arm 110 of the alignment structure 104 a-104 d to the base 102 at a desired position. Any other suitable moveable structure is contemplated herein. It is contemplated that the extension arms 110 can be fixed to the base in certain embodiments.

Each alignment structure 104 a-104 d can further include one or more alignment support members 112 connected to each alignment structure 104 a-104 d and extending into and/or over the alignment opening 106 a-106 d. Each alignment support member 112 can be configured to contact a leg 132 disposed in the alignment opening 106 a-106 d (e.g. as shown in FIG. 9). The one or more alignment support members 112 can be complementary to a surface 142 of a respective leg 132 and are positioned to contact the respective leg 132 in flush contact (e.g. as shown in FIG. 9). The one or more alignment support members 112 can be positionably mounted to each alignment structure 104 a-104 d to allow each alignment support member 112 to be positioned relative to a respective leg 132 disposed within the alignment opening 106 a-106 d. For example, as shown in FIGS. 6A-6D, the alignment support member 112 can have a plurality of holes 114 along a longitudinal length 116, the plurality of holes 114 can be configured to engage a respective pin 118 on the alignment structure 104 a-104 d, securing the alignment support member 112 in a desired position.

In embodiments, the plurality of alignment structures 104 a-104 d can include a complimentary shape to the two or more legs 132. For example, each alignment structure 104 a-104 d can be a shape complementary to a caisson having a substantially polygonal shape, such as a dodecagon as shown in FIG. 1. For example, the alignment structure 104 a-104 d can be a shape complimentary to a leg of a Pyramax® tower made by Valmont Industries, Inc., having a principle place of business of 28800 Ida Street Valley, Nebraska USA 68064. Any suitable shape can be used.

In certain embodiments, the base 102 can form a substantially planar shape (e.g. as shown in FIG. 1). The alignment openings 106 a-106 d of each alignment structure 104 a-104 d can also include an opening planar vector V1 that can be substantially parallel to a base planar vector V2 of the planar shape of the base, for example as shown in FIG. 5. In embodiments, the substantially planar shape can be a square shape (e.g. as shown in FIG. 1).

The base 102 can further include a support frame 120 and a platform 122 supported by the support frame 120. The base 102 include a first side 124 and a second side 126 that can be detachably connected (e.g., via bolts as shown in FIG. 3) to each other along a midline M, for example. This can allow an otherwise too-large-for-ground-transport structure to be split into components and shipped to a job site or pick up location, for example. Any suitable number of pieces is contemplated herein. In certain embodiments, the support frame 120 may be a singular piece welded or otherwise fixed together.

The device 100 can also include at least one pair alignment baffles 128 configured to receive a portion of a pile driver 108 on the platform 122 (e.g. as shown in FIG. 2). Each pair of alignment baffles 128 can be configured to receive a foot 109 of a pile driver 108 (e.g. as shown in FIG. 9). For example, the pair of alignment baffles 128 can be complimentary to a shape of a foot 109 of a pile driver 108. In embodiments, the at least one pair of baffles 128 can be at least one inch in height, however any suitable height can be used.

The base 102 can also include a plurality of connection points 130 (e.g., as shown in FIG. 2) that can be configured to connect to a lifting device, such as a helicopter or crane, for lifting and/or transport of the alignment device 100. The connection points 130 can include a D-ring type connector, for example, or any other suitable connector.

Turning to FIG. 9, device 100 can be disposed on a surface 134, and a pile driver 108 can be disposed on the platform 122 of the device 100 via a lifting device (e.g., a helicopter). The alignment baffles 128 can assist in properly aligning the feet 109 of pile driver 108 with the device 100. A lifting device can place a leg 132 of a structure within an alignment structure 104 a-104 d (e.g., an open, closeable, or closed alignment structure). In certain embodiments, the alignment structure can be closed around the leg 132, or the leg 132 can be inserted into the already closed alignment structure. Alignment support members 112 can be adjusted to support the leg 132 during alignment and/or during pile driving.

In accordance with at least one aspect of this disclosure, a method can include constructing a structure having a plurality of legs 132 using an alignment device 100 configured to align each leg 132 relative to each other. The method can include disposing an alignment device 100 onto a surface 134. Disposing the alignment device 100 can include lowering the alignment device 100 from a lifting device, e.g., a helicopter.

The method can include disposing a pile driver 108 onto the alignment device 100. Disposing the pile driver 108 can include lowering the pile driver 108 from a lifting device, for example, a helicopter.

In certain embodiments, the method can also include placing a first leg of the structure into a first alignment structure 104 a of the alignment device 100, and pile driving the first leg of the structure into the surface 134 using a pile driver 108 supported by the alignment device 100. The method 200 can include placing a second leg of the structure into a second one of the alignment structures 104 b of the alignment device 100. The method can include turning the pile driver 108 to interact with the second leg and/or to align the pile driver 108 with the second one of the at least one alignment structures 104 a. The method can include pile driving the second leg of the structure into the surface 134 using the pile driver 108. The method can include any other suitable method(s) and/or portions thereof, and can be performed in any suitable order (e.g., as described above or in any other suitable order).

In accordance with at least one aspect of this disclosure, a method can include constructing a multi-legged utility tower having a plurality of legs 132 on wetland (shown generally as surface 134) using an alignment device 100 configured to rest on the wetland surface 134 to align at least two of the plurality of legs 132. The multi-legged utility tower can be an electrical transmission structure. For example, the multi-legged utility tower can be a Pyramax® tower made by Valmont Industries, Inc., having a principle place of business of 28800 Ida Street Valley, Nebraska USA 68064. However, the tower can be any large multi-legged tower. The method can include any other suitable method(s) and/or portions thereof, and can be performed in any suitable order (e.g., as described above or in any other suitable order).

Embodiments disclosed herein can be of any suitable or desired size. Embodiments can be made of any suitable materials (e.g., iron, steel). Embodiments can include any suitable number of alignment structures and support member on each alignment structure. The alignment structures can have any suitable structure configured to support legs to allow alignment of a plurality of legs. Any other suitable modifications are contemplated herein.

Those having ordinary skill in the art understand that any numerical values disclosed herein can be exact values or can be values within a range. Further, any terms of approximation (e.g., “about”, “approximately”, “around”) used in this disclosure can mean the stated value within a range. For example, in certain embodiments, the range can be within (plus or minus) 20%, or within 10%, or within 5%, or within 2%, or within any other suitable percentage or number as appreciated by those having ordinary skill in the art (e.g., for known tolerance limits or error ranges).

The articles “a”, “an”, and “the” as used herein and in the appended claims are used herein to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article unless the context clearly indicates otherwise. By way of example, “an element” means one element or more than one element.

The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.

As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e., “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.”

Any suitable combination(s) of any disclosed embodiments and/or any suitable portion(s) thereof are contemplated herein as appreciated by those having ordinary skill in the art in view of this disclosure.

The embodiments of the present disclosure, as described above and shown in the drawings, provide for improvement in the art to which they pertain. While the subject disclosure includes reference to certain embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the spirit and scope of the subject disclosure. 

What is claimed is:
 1. An alignment device for assembling a structure having two or more legs, comprising: a base configured to support a pile driver for pile driving at least one of the two or more legs; a plurality of alignment structures configured to define an alignment opening, connected to the base, and extending at least partially laterally from the base, wherein the plurality of alignment structures are configured to receive a respective leg of the two or more legs to allow the two or more legs to be positioned relative to each other.
 2. The alignment device of any preceding claim, wherein each alignment structure further comprises one or more alignment support members connected to each alignment structure and extending into and/or over the alignment opening, each alignment support member configured to contact a leg disposed in the alignment opening.
 3. The alignment device of claim 2, wherein the one or more alignment support members are complementary to surface of a respective leg and are positioned to contact the respective leg in flush contact.
 4. The alignment device of claim 3 or 4, wherein the one or more alignment support members positionably mounted to each alignment structure to allow each alignment support member to be positioned relative to a respective leg disposed within the alignment opening.
 5. The device of any preceding claim, wherein the plurality of alignment structures include a complimentary shape to the two or more legs.
 6. The alignment device of claim 5, wherein each alignment structure is complementary to a caisson having a substantially polygonal shape.
 7. The alignment device of claim 6, wherein each alignment structure is a dodecagon.
 8. The device of any preceding claim, wherein the base forms a substantially planar shape.
 9. The device of any preceding claim, wherein the alignment opening of each alignment structure includes an opening planar vector that is substantially parallel to a base planar vector of the planar shape of the base.
 10. The device of claim 9, wherein the substantially planar shape is a square shape.
 11. The device of claim 1, wherein the base includes a support frame and a platform supported by the support frame.
 12. The device of claim 11, wherein the base includes a first side and a second side detachably connected to each other along a midline.
 13. The alignment device of claim 1, further comprising at least one pair alignment baffles configured to receive a portion of a pile driver on the platform.
 14. The alignment device of claim 13, wherein the each alignment baffle is configured to receive a foot of a pile driver and/or are complimentary to a shape of a foot of a pile driver.
 15. The alignment device of claim 14, wherein the at least one pair of baffles are at least one inch in height.
 16. The alignment device of claim 1, further comprising a plurality of connection points configured to connect to a lifting device for lifting and/or transport of the alignment device.
 17. A method, comprising: constructing a structure having a plurality of legs using an alignment device configured to align each leg relative to each other.
 18. The method of claim 17, further comprising disposing an alignment device onto a surface; wherein disposing alignment device includes lowering the alignment device from a helicopter.
 19. The method of claim 18, further comprising disposing a pile driver onto the alignment device; wherein disposing the pile driver includes lowering the pile driver from a helicopter.
 20. The method of 17, comprising: placing a first leg of the structure into a first alignment structure of the alignment device; and pile driving the first leg of the structure into the surface using a pile driver supported by the alignment device.
 21. The method of claim 20, further comprising: placing a second leg of the structure into a second one of the alignment structures of the alignment device; turning the pile driver to interact with the second leg and/or to align the pile driver with the second one of the at least one alignment structures; and pile driving the second leg of the structure into the surface using the pile driver.
 22. A method, comprising: constructing a multi-legged utility tower having a plurality of legs on wetland using an alignment device configured to rest on the wetland surface to align at least two of the plurality of legs.
 23. The method of claim 22, wherein the multi-legged utility tower is an electrical transmission structure. 